PTC Thermistor Protective Device with Integrated Housing
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Solution Overview
Problem
Existing electrical protection devices for telecommunications are costly to produce and do not meet the requirements for low overall height and simplicity in design.
Innovation Solution
A protective device featuring two disc-shaped PTC thermistor components arranged in a common, one-piece housing with cylindrical openings for easy insertion and electrical isolation, using connecting wires for both electrical contact and fixation, eliminating the need for complex threading and ensuring compliance with telecommunications standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional electrical protection devices are used, then protection function is provided, but production cost is high and overall height is large
Solution Approach 1:
The patent merges multiple functions into a single integrated housing structure. The housing combines support, insulation, and fixation functions for the PTC components, eliminating the need for separate mounting brackets, insulation pieces, and fixation elements. This integration reduces the number of parts, simplifies production, lowers costs, and reduces overall height by eliminating intermediate structural elements.
Solution Approach 2:
The housing is designed as a multi-functional component that simultaneously provides mechanical support, electrical insulation, component fixation, and structural containment. The integrated design makes the housing serve multiple purposes that traditionally required separate components, thereby reducing overall device height and production complexity.
2Productivity
If complex threading of connecting wires into bushings is used, then electrical contact is achieved, but production time and cost increase
Solution Approach 1:
The patent extracts and eliminates the complex wire threading process by integrating electrical contact functionality directly into the housing structure. Connection terminals are built into the housing, allowing wires to be simply connected without threading through separate bushings or conduits. This extraction of the threading step significantly reduces production time and complexity.
Solution Approach 2:
The housing is pre-designed with integrated connection terminals and wire routing paths during manufacturing. This preliminary preparation of connection points eliminates the need for time-consuming wire threading operations during assembly, as wires can be directly connected to pre-positioned terminals.
3Device complexity
If multiple separate components are used, then functional requirements are met, but device complexity and production cost increase
Solution Approach 1:
The patent combines multiple separate components (housing, mounting structure, insulation elements, fixation mechanisms) into a single integrated housing unit. This merging reduces the total number of parts, simplifies assembly, and lowers production costs while maintaining all necessary protection functions through the integrated design.
Solution Approach 2:
The integrated housing performs multiple functions simultaneously - mechanical support, electrical insulation, component fixation, and environmental protection - that traditionally required separate components. This multi-functionality maintains reliability while reducing device complexity and component count.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution allows for a cost-effective production process with a low overall height, meeting safety regulations and enabling easy integration into electrical circuits while providing effective protection against line failures and interference.
Implementation Method 1
two PTC thermistor components (1) arranged in a common housing (2)
Data Source
Figure 1~2
Figure 3~4
AI summary
Disclosed is an electrical protective device comprising two disk-shaped PTC thermistor components (1) that are arranged in a common housing (2). The housing (2) has an opening (3) on each of two opposite sides, said opening (3) corresponding to the dimensions of the PTC thermistor components (2) such that the PTC thermistor components (2) can be inserted into the housing through the openings (3). The two PTC thermistor components (1) are electrically insulated from one another inside the housing (2). The PTC thermistor components (1) each have at least two connecting wires (4), by means of which the PTC thermistor components (1) are locked to the housing (2).